Stacking and Wrapping System and a Method of Using Same

The present disclosure relates to systems for wrapping and stacking products. The system is particularly suited for stacking and wrapping fragile products such as thin cells.

It is well known in the art that packaging fragile products can be very challenging. Some products may be damaged by exerting any pressure on the product.

Accordingly, it would be advantageous to provide a stacking and wrapping system that may be used with fragile products.

A further understanding of the functional and advantageous aspects of the disclosure can be realized by reference to the following detailed description and drawings.

A stacking and packing system is for stacking and packing a plurality of products with a wrap. The stacking and packing system includes a Z stacking subsystem, a pick and place subsystem and a wrap management subsystem. The Z stacking subsystem has a stacking zone and is configured to stack the plurality of products and position the wrap between each of the plurality of products to form a plurality of stacked and wrapped product. The pick and place subsystem is configured to place one of the plurality of products onto the stacking zone. The wrap management subsystem is configured to move the wrap to the stacking zone.

The Z-stacking subsystem may include a first wrapping pin assembly having a first wrapping pin and a second wrapping pin assembly having a second wrapping pin wherein the second wrapping pin is spaced from the first wrapping pin. The first wrapping pin and the second wrapping pin may be configured to be positioned on opposing sides of one of the plurality of products when positioned in the stacking zone.

The first wrapping pin and the second wrapping pin may be spaced from one of the plurality of products when positioned in the stacking zone.

The first wrapping pin and the second wrapping pin may be configured to move from an engaged position to a rest position wherein in the engaged position the first wrapping pin and the second wrapping pin may be on opposing sides of the stacking zone and in the rest position may be spaced from the stacking zone.

The first wrapping pin and the second wrapping pin may slide outwardly from the engaged position to the rest position generally horizontally.

The Z-stacking subsystem further includes a first foot assembly may have a first foot and a second foot assembly having a second foot wherein the second foot is spaced from the first foot.

The first foot and the second foot may each be configured to move from an engaged position to a rest position.

The engaged position for each of the first foot and the second foot may be in registration with the first wrapping pin and the second wrapping pin respectively.

The pick and place subsystem may include a suction head for picking up one of the plurality of products.

The wrap management subsystem may be configured to move the wrap backwardly and forwardly over the loading zone.

The wrap management subsystem may be further configured to tension the wrap as it moves backwardly and forwardly over the loading zone.

The stacking and packing system may further include a movement system for of the plurality of stack and wrapped product.

The plurality of products may be a plurality of thin cells.

The wrap may be a single continuous wrap.

The plurality of products may include alternating anodes and cathodes and the wrap is a packing material wherein the wrapped and stacked product forms a battery cell.

A Z stacking system for use with a product and a wrap includes a stacking zone for receiving the wrap and a product thereon; a first wrapping pin assembly having a first wrapping pin and a second wrapping pin assembly having a second wrapping pin wherein the second wrapping pin is spaced from the first wrapping pin on opposing sides of the stacking zone; and a first foot assembly having a first foot and a second foot assembly having a second foot wherein the second foot is spaced from the first foot on opposing side of the stacking zone.

The first wrapping pin and the second wrapping pin may be configured to be spaced from the product

A method of stacking and packing a plurality of products having wrap therebetween using a first pin, a corresponding first foot, a second pin, and a corresponding second foot, the method comprises the steps of:

The sequence of step f) and sequence of step m) may be variable.

The product in step c) may be a first product and the product in step j) may be a second product. The first product may be an anode and the second product may be a cathode. The wrapped and stacked plurality of products may be a battery.

The wrap may be tensioned.

The first wrapping pin and the wrapping second pin may be moved from the engaged position to the rest position generally horizontally.

The method of stacking and packing may further include the step of moving the wrapped and stacked plurality of products to a predetermined location.

The first wrapping pin and corresponding first foot may be in registration in the engagement position.

Various embodiments and aspects of the disclosure will be described with reference to details discussed below. The following description and drawings are illustrative of the disclosure and are not to be construed as limiting the disclosure. Numerous specific details are described to provide a thorough understanding of various embodiments of the present disclosure. However, in certain instances, well-known or conventional details are not described in order to provide a concise discussion of embodiments of the present disclosure.

As used herein, the terms “comprises” and “comprising” are to be construed as being inclusive and open ended, and not exclusive. Specifically, when used in the specification and claims, the terms “comprises” and “comprising” and variations thereof mean the specified features, steps or components are included. These terms are not to be interpreted to exclude the presence of other features, steps or components.

As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not be construed as preferred or advantageous over other configurations disclosed herein.

As used herein, the terms “about” and “approximately” are meant to cover variations that may exist in the upper and lower limits of the ranges of values, such as variations in properties, parameters, and dimensions. Unless otherwise specified, the terms “about” and “approximately” mean plus or minus 25 percent or less.

It is to be understood that unless otherwise specified, any specified range or group is as a shorthand way of referring to each and every member of a range or group individually, as well as each and every possible sub-range or sub-group encompassed therein and similarly with respect to any sub-ranges or sub-groups therein. Unless otherwise specified, the present disclosure relates to and explicitly incorporates each and every specific member and combination of sub-ranges or sub-groups.

As used herein, the term “on the order of”, when used in conjunction with a quantity or parameter, refers to a range spanning approximately one tenth to ten times the stated quantity or parameter.

As used herein the “operably connected” or “operably attached” means that the two elements are connected or attached either directly or indirectly. Accordingly the items need not be directly connected or attached but may have other items connected or attached therebetween.

It is to be noted that the specification and claims of the application and the terms “first”, “second” and the like in the drawings are used to distinguish similar objects, and do not need to describe a specific sequence or a precedence order. It will be appreciated that data used in such a way may be exchanged under appropriate conditions, in order that the embodiments of the application described here can be implemented in a sequence other than sequences graphically shown or described here. In addition, terms “include” and “have” and any variations thereof are intended to cover non-exclusive inclusions. For example, it is not limited for processes, methods, systems, products or devices containing a series of steps or modules or units to clearly list those steps or modules or units, and other steps or modules or units which are not clearly listed or are inherent to these processes, methods, products or devices may be included instead.

Referring to thea stacking and packing system is shown generally at. The stacking and packing system is for stacking and packing a plurality of products with a wrap. The stacking and packing systemincludes a Z stacking subsystem, a pick and place subsystemand a wrap management subsystem. The stacking and packing systemfurther includes a product delivery systemfor delivery the product to the pick and place subsystem. It also includes a movement systemfor the stacked and wrapped product.

Referring to, the Z stacking subsystemhas a stacking zone defined by the first wrapping pinand a second wrapping pin. In the embodiment shown herein the dimensions of the stacking zone are determined by the dimensions of the intended product. The first wrapping pinand the second wrapping pinare spaced apart and configured to be positioned on opposing sides of the product. The wrapping pinsandare configured to not touch the product or stated another way are configured to be spaced from the products. The wrapping pinsandare stiff enough for the wrapto wrap around them. The wrapping pinsandare moveable from an engaged position when they are on opposed sides of the stacking zone and holding a wrapin position. Each wrapping pinis held in position with a wrapping pin assemblyas best seen in.

The wrapping pin assemblyis a modular assembly that is configured to move the wrapping pinforwardly and backwardly along rails, inwardly and outwardly along railsand upwardly and downwardly along rails. Servo motors are used to drive the wrapping pin assemblyin the different directions.

The stacking and packing systemalso includes a first footand a second foot. The first footand the second footare configured to be positioned in registration with the first wrapping pinand second wrapping pinrespectively. The first footand the second footare moveable from an engaged position to a rest position. The first footis in an engaged position when the foot is positioned over the wrapping pinand is pushed on the wrap. Each footis held in place with a foot assemblybest seen in.

The foot assemblyis a modular assembly that is configured to move first footforwardly and backwardly along rails, inwardly and outwardly along railsand upwardly and downwardly along rails. Servo motors are used to drive the wrapping pin assemblyin the different directions. The first footis generally elongate with a flat bottomwhich has a grooveformed therein. The grooveis formed therein so that the first footcan fit over the first wrapping pin.

The stacking and packing systemincludes an intermediate platformas shown in.

The wrap management subsystemis shown in. A spoolof the wrapis rotatably attached to the wrap management subsystem. Preferably the wrapis a single continuous wrap. The wrapis fed through a series of pulliesto aid in the tensioning of the wrap. The wrap management subsystemincludes a linear actuatorconfigured to move the wrap backwardly and forwardly over the stacking zone.

The pick and place subsystemis shown generally in. The pick and place subsystemincludes a robotic arm. A suction headis attached to robotic arm. The suction headis for loading the productonto the stacking zone.

The stacking and packing system may further include a movement system for of the plurality of stack and wrapped product.

In the embodiment shown herein the product is a thin cell. More specifically the products are fragile anodes and cathodes and the wrap is a specific packing material called a separator. In the embodiment shown herein the product being positioned on the wrap alternates between an anode and a cathode. Collectively the anodes, cathodes and separator form a battery cell.

However, it will be appreciated by those skilled in the art that this stacking and packing system may be adapted to be used with a variety of different products and in different industries. For example, the products being packaged together need not all be the same product. As discussed above the products may alternate between two specific products. For example, it may be used in food processing, battery manufacturing, jewelry packaging or any industry that requires handling of fragile goods.

In use, the stacking and packing systemis used to make a stacked and wrapped product that consists of a plurality of products separated by wrap. Referring to, a flow chart shows the specific steps in the process. More broadly the process has three main phases, namely the initialization phase, the Z packaging phase, and the securing packaging and uploading phase.

The initialization phase is to prepare the packaging system to start packaging the product. This phase includes three steps that follow each other: step 1—installing the wrap at the start position, step 2—rolling the wrap over the packaging surface and step 3—lowering the wrapping pins in position on the wrap to immobilize the wrap.

The initialization phase of the process sets up all of the required setttings for the packaging step to happen, in the embodiment shown herein of stacking batteries components. The initial step is to setup the packaging wrap properly, which includes deploying it on the packaging surface.